Crimping apparatus for treating fibers



Aug. 29, 1961 -c. J. Russo r-:T AL 2,997,747

CRIMPING APPARATUS FOR TREATING FIBERS Filed Deo. 2l, 1959 4Sheets-Sheet 1 Aug. 29, 1961 c. J. Russo ET AL 2,997,747

CRIMPING APPARATUS FOR TREATING FIBERS Filed Deo. 2l. 1959 4Sheets-Sheet 2 A LexA N055 17' fra/va v/c @M SVK' I, r I

A TTORNE'Y Aug. 29, 1961 c. J. Russo ET AL 2,997,747

CRIMPING APPARATUS FOR TREATING FIBERS Filed Dec. 2l, 1959 4Sheets-Sheet 3 Aug. 29, 1961 c. J. Russo ET AL CRIMP'ING APPARATUSFORTREATING FIBERS 4 Sheets-Sheet 4 Filed Dec. 2l. 1959 United StatesPatent O CRIMPING APPARATUS FOR TREATING FIBERS Carl J. Russo, Newark,and Alexander L. Trifunovic, Wilmington, Del., and Henry A. Sinski,Alden, Pa., assignors to Joseph Bancroft & Sons Co., Wilmington,

'Del., a corporation of Delaware Filed Dec. 21, 1959, Ser. No. 861,001

11 Claims. (Cl. 19-66) This invention relates to a method and apparatusfor crimping, packaging andl treating textile fibers and has for anobject to provide a method and apparatus of the above type having noveland improved characteristics.

Another object is to provide an apparatus of the above type whichpackages the crimped fibers in the form of a core which is wound in aplurality of layers on a pervious support of the type used for packagedyeing and is held in compacted form by a tape to prevent the core fromopening during the treating steps.

Another object is to provide such an apparatus wherein the core is laidldirectly onto the package as it is gripped by the tape and is heldwithout loss of compacting pressure.

Another object is to provide novel and improved apparatus for removingthe treated yarn from the package.

Another object is to provide -a novel and'improved method and means forcrimping and processing yarns of various types.

Another object is to provide a yarn package wherein the crimped yarn isadapted -to be processed in standard processing equipment.

Various other objects and advantages will be apparent as the nature ofthe invent-ion is more fully disclosed.

The nature of the invention will be better understood from the followingdescription, taken in connection with the accompanying drawings in whicha specific embodiment has been shown for purposes of illustration.

In the drawings:

FIG. l is a vertical section illustrating an appa-tatu according to theinvention;

. FIG. 2 is a partial horizontal section taken on the line 2-2 of FIG.1;

FIG. 3 is -a partial vertical section taken on the line 3-3 of FIG. 1;

FIG. 4 is a top plan view of the apparatus of FIG. l;

FIG. 5 is an elevation of a completed package with parts broken away toshow the interior;

FIG. 6 is a block diagram illustrating representative steps in thetreating process;

FIG. 7 is -a side elevation of an apparatus for unwinding the packagewith parts broken away to show the structure; and l FIG. 8 is a sectiontaken on the line 8 8 of FIG. 7.

Referring to the drawings more in detail, the invention is shown asembodied in a stuffer crimper comprising a base plate 1 carrying aheating and crimping block 2 having a bore in which a sleeve 3 is lixedas by a press fit. A crimping tube 4 is held in the sleeve 3 by aclamping nut 5 on the lower tapered, split end 6 of the sleeve 3. Asource of heat, such as a resistance rod 7 is held in a bore in theblock 2 parallel to the tube 4. A pair of feed rolls 10 and 11 arepositioned to feed the fibers into the lower end of the tube 4 to befolded over and crimped against the pressure of 'a mass of previouslycrimped fibers held compacted in the tube 4. The feed roll 10 is mountedon a shaft 12 which is journalled to rotate in a bearing 13 supported bythe block 2. The feed roll 11 is mounted on a shaft 14 carried in apivoted bracket v15 carried by the block 2 and having an arm 16 pressedby a spring 17 to hold the roll 11 in feeding engagement with the roll10. The rolls 10 and 11 are driven bygears 18 to operate in unison. 4Theshaft 12 is driven by a N Patented Aug. 29, 1961 .ice

drive motor not shown, preferably through a constant torque clutch sothat a constant pressure is maintained on the fibers as they are fedinto and crimped in the crimping chamber in the tube 4.

In the form shown, the fibers 20 are fed between rolls 21 into apretreating tank 22, thence through the tank 22 and between rolls 23into a heater or dryer 24. Thence through a tension device 25 and aguide 26 to the bite of the feed rolls 10 and 11.

The upper end of the tube 4 is formed with a rounded top surface 30 andextends through a central ange 31 in a block 32 carried by the block 2.A feed tube 33 forming an extension of the tube 4, is formed with acurved bottom wall 34 seating on the top wall 30 of the tube 4 andcarries at its lower end a block 35 having side flanges 36 spanning thecentral flange 31 of the block 32 and having a curved lower sufrace 37seating on the top surface 38 of the ange 31` so as to -allow the tube33 to pivot about the upper end of the tube 4 for the purpose to bedescribed.

The upper end of the tube 33 is formed with an arcuate surface 39 to laythe core of crimped bers 40 which is discharged therefromin successiveconvolutions on a package 41. The discharge end of the tube 33 is heldagainst the package 41 by -a spring 27 connectedby eyes 28 and 29 toblocks 35 and 32, respectively.

The package 41 isshown as wound on a perforated tube 42 of the type usedfor package dyeing. The tube 42 is mounted on a sleeve 43 which isslidably mounted on a shaft 44 and is keyed thereto by a key 45. Theshaft 44 is driven from a gear box 46 through a constant torque clutchof any standard type. A cam 47 driven by lthe gear box 46 actuates atraversing slide 48 having at its end a yoke riding in a groove formedin the sleeve 43 to reciprocate the sleeve 43 for laying the core 40 insuccessive convolutions and in successive layers on the tube 42. 'Ihegear box may be driven by a suitable motor.

A tape 50 is held on a reel 51 mounted on a bracket 52 attached to thebase plate 1. The tape 50 is fed through the forked end 53 of a pivotedarm 54 to a feed roll 55 having a roughened surface, thence around a pin56 and over a lever 57 pivoted to the bracket 52 and over a guide roll58 mounted on a bracket 59 carried by the feed tube 33 under a guideroll 60 mounted on the bracket 59 adjacent the discharge end of the tube33 to lay the tape 50 over the core 40 of crimped fibers as they are fedfrom the end of the tube 33 onto the package 41. The lever 57 carries anarm 61 which is positioned to actuate a microswitch 62, which isconnected to control the operation of the entire machine. A constantspeed motor 63 drives the roll 55. The end 64 of the arm 54 is providedwith a surface 65 which is adapted to hold the -tape 50 in grippingengagement with the feed roll 55.

In winding the package 41 a sock 66 is placed over the tube 42 and alayer of the tape 50 is wrapped therearound. As the core 40 isdischarged from the end of 'the tube 33 beneath the tape 50 it is heldcompacted in its original cross section by the pressure of the tape asit is wound in successive convolutions and successive layers on theperforated tube 42 until a package of the desired size has -been builtup. The feed of .the tape is controlled by the feed roll 55 which isactuated by the drive motor 63.

In operation the mass of crimped fibers is discharged from the end ofthe feed tube 33 in the form of a core having the same cross section asthe tubes `4 and 33 and is in effect stuffed into the space between thetape 50 and the previous layerof winding where it is held in compactedform without any chance to open up or relax its crimped form. It isconfined on the package 41 between tapes 50 in the form of a pluralityof convolutions in several layers with the core of crimped fibers inadjacent convolutions bound and separated by the interveningconvolutions of tape.

After the package has been wound to the desired size the winding isstopped, the package removed from the sleeve 43 while still on the tube42 and the sock 66 is turned over the package from both ends to form aconfining cover as shown in FIG. 5. This package is then of the size andform adapted for treatment in the usual package `dyeing apparatus.

The microswitch 62 is adapted to stop the machine including the variousdrive motors yand heating elements in response to a breakage or runningout of tape '50. When the end of the tape passes the lever 57 the leveris released to release the microswitch 62 and thereby stop the machine.

In order to permit the machine to be started up, for example, forwarming the crimping chamber prior to the actual beginning of thecrimping operations, the arm 54 is raised from 4the feed roll 55 therebypermitting the feed roll to turn without feeding the tape. The arm 54 isheld in this position by engagement with the lever 57 and thus causesthe lever 57 to maintain the switch 62 closed during this warm upperiod. The lever 57 is moved counterclockwise to close the switch 62and is held in this position by the arm 54.

The packing of the core in the winding is determined by the r-ate offeed of the tape 50 with respect to the feed of the feed rolls 10, 11.'Ilhese elements may be driven at a constant but adjustable ratio or thefeed rolls and 11 may be driven through a constant torque clutch inwhich event the rate of feed is controlled by the back pressure on thefibers due to the tension of the tape 50 as it is wound on the package41. The tape 50 envelops the end of the tube 33 in a sufiiciently closemanner to control the back pressure exerted on the mass of crimpedfibers Within the tubes 4 and 33. The pressure exerted on the fibers maythus be controlled by varying the rate of feed of the tape 50 or therelative speed of the tape feed with relation to the feed rolls =10, 11.

For processing, a plurality of packages 41 of crimped fibers are stackedon perforated tubes in a dye vat which may be closed to permit atreating liquid or vapor such as steam or wash water or hot air as thecase may be to be forced through the package from the inside to theoutside or vice versa depending upon the particular treatment stepinvolved. The packages may then be dried or excess treating liquidremoved in a centrifuge or the packages may be placed in an oven for thefinal drying or curing step. If the package is to be treated underpressure as by steam or by heated air for drying, the packages may beplaced in an autoclave. In any event the fibers on the perforated tube42 are pervious and readily treated by known techniques.

The process may be applied to natural fibers such as wool or cotton inthe form of a roving, or to silk in twisted or untwisted form, or tocontinuous filament synthetic fibers in the form of a tow or in the formof a yarn. In the case of wool the roving may be presoftened by hotwater or steam in the tank 22 and dried to a predetermined moisturecontent in the dryer 24, then crimped in the stufer crimper and thepackage subjected to steam treatment or to hot water and dried in yanoven or autoclave to set the crimp while the fibers are held compactedin the package. In the case of cotton or synthetic cellulosic fiberssuch as rayon or facet-ate the fibers may be pretreated by heat andmoisture as above, crimped and packaged, then subjected to heat andmoisture under pressure and `dried to set the crimp. Alternatively, theoellulosic fibers may be impregnated with a thermosetting resin inthetank 22, partially dried in the dryer 24, crimped and packaged as above,and the package dried to resin curing temperature in an oven. As afurther example the cellulosic fibers may be crimped and packaged, thepackage impregnated by a resin and catalyst, then centrifuged to removeexcess impregnant, cured in an oven, washed and dried.

Other synthetic fibers may be preheated for softening, crimped,packaged, subjected to heat and moisture in a closed vessel, and driedin an oven. In all of these cases it is possible to utilize a treatingcycle of several minutes or even hours regardless of the speed ofoperation of the crimping apparatus.

After treatment the fibers may be removed from the package and processedinto yarn in the usual manner. In the case of staple fibers such as woolor cotton the package is unwound, the core removed and the fibers openedup for spinning. In the case of continuous filaments the tape may beunwound to expose the core and the tow or yarn pulled from the core asit is exposed and wound onto a cone or otherwise packaged for furtheruse. This may be effected by hand or by the unwinding and packaging`apparatus shown in FIGS. 7 and 8, to be described.

FIG. 6, for example, illustrates a process which involves first passinga treating solution through the package, then drying, then applying animpregnating agent, extracting the excess impregnating agent as bycentrifuging, then drying and curing as in a heating oven for settingthe impregnant, followed by conditioning the yarn as by the applicationof sizing and then rewinding.

Cellulosic yarns whether spun or filament should have a moisture contentapproximating their natural moisture content at 65% relative humidityand 70 F. before enterfing the crimper. If the moisture is appreciablybelow the natural moisture content the fibers are too brittle. If themoisture is more than -about 21/2 times the natural moisture, the fiberstend to stick to the walls of the crimper.

All fibers except those that melt below about 212 F. may be used in theprocess. This would include most of the thermoplastic fibers and all ofthe cellulosics such as cotton, regenerated cellulose rayon, linen,rarnie, jute, etc.

In the case of cellulosics it is necessary to treat the fibers so as tomake the artificial crimp durable to washing and/or dry cleaning.

Following are various examples of the sequence of steps which may beused in carrying out the invention for cellulosic fibers.

(l) The yarns may be treated with a crimp fixative and partially driedbefore entering the crimping chamber, then crimped, packaged, cured inthe package, and finally unwound.

(2) The yarns may be crimped, packaged, treated with the crimp fixativein the package, cured in the package and finally unwound.

As the crimp fixative a few of the many materials that can be used aredimethylol ureas, di or tri-methylol melamines, methylated methylolureas, methylated methylol melamines, dimethylol ethylene ureas,dimethylol propylene ureas, dimethylol triazones, formaldehyde, etc.

The following examples are illustrative (parts are by weight unlessotherwise indicated):

Example I 980 parts methylated methylol melamine solids) 210 partsMgC126H2O 12 parts wetting agent Water to 10,000 parts 200 denier 211/2S twist 44 ament viscose rayon is wound on a Franklin type dye spring.Several such packages yare placed in a dye package machine andimpregnated with the above solution by pumping the solution fromthe'inside to the outside for 15 miutes, follower by pumping thesolution from the outside to the inside for 15 minutes.

The packages are then extracted for 6 minutes in a centrifugal extractorso that the yarn retains about 64% of the impregnating solution, thatis, 1 1b. of the yarn contains about 0.64 1b. of the impregnatingsolution.

After extraction the yarn is dried to about 17% moisture in an ovenywith circulating air at about 210 F.

The impregnated yarns are then crimpedV using a heated core type crimperas `described above to form a core which is Wound onto a Davidson typespring using 15/8 inch cotton tape. The cotton tape has a greigeconstruction 56 x 44 176 yds/lb.

The packaged yarn is cured in a 'heated atmosphere at about 260 F. forabout 30 minutes. After curing the crimped yarn is unwound and oiled ifnecessary. The yarn is then ready for knitting.

Example II 200 denier 3 S twist 40 filaments viscose rayon yarn iscrimped in the heated crimping chamber as described above at 320yds/min. entering speed and wound on Franklin type springs using 1% inchcotton tape at 26 inch/min. Several packages of the crimped yarn on theFranklin type springs are placed in a package dye unit and treated withthe following crimp fix-ative:

2496 parts methylated methylol melamine (80% solids) 780 parts magnesiumchloride hexahydrate (70% solids) 32 parts wetting agent diluted to26,000 parts with water Example III 300 denier 31/2 S twist 60 filamentsblue viscose rayon is processed as in Example II to give a durable crimpthat is fast to washing and dry cleaning.

Example IV 200 denier 21/2 S twist 44 filaments bright filament viscoseyarn is treated as in Example II except that the following mix is usedto x the crimp:

1875 parts dimethylol ethylene urea (50% solids) 240 parts zinc nitratehexahydrate (70% solids) 24 parts acetic acid 75% 75 parts polyvinylalcohol 420 parts glycerine 16 parts wetting agent diluted to 13,000parts with Water The crimp is durable to washing and dry cleaning afterbeing made into a knitted or woven fabric.

Example V Size 30 bleached cotton yarn is handled as in Example I exceptthat the following crimp 'rixative is used in place of the one inExample I:

800 parts dimethylol ethylene urea (5 0% 20 parts 2 amino-2 methyl-1propanol hydrochloride parts wetting agent Water to 10,000 parts Thecrimp is durable to washing and dry cleaning.

Example Vl Size 26 bleached cotton yarn is impregnated with thefollowing mixture:

200 parts formaldehyde 10 parts zinc nitrate hexahydrate (70%) 1 partwetting agent diluted to 1,000 parts with water by running the yarn intoa tank containing the mixture, the yarn then goes between squeezerollers to remove the excess solution. The impregnated yarn is dried toabout 10% moisture by passing it through a chamber heated to about 220F. The partially dried yarn is then crimped as described above and woundonto the core packages. The core package is heated for about 40 minutesby pass- Example I is repeated except that the package of crimped yarnis cured for 25 minutes in an autoclave where the steam pressure insidethe autoclave is 45-50 lbs. A durable crimp is obtained.

Example VIII Example II is repeated exceptthat the following mixture wasused:

950 parts methylated methylol melamine solids) 210 parts magnesiumchloride hexahydr-ate 10 parts wetting agent parts water Isopropylalcohol is added to make 10,000 parts. durable crimp is obtained.

Example IX Example Il is repeated except that a linen yarn is used. Adurable crimped linen yarn is obtained.

Example X Silk yarn, either spun staple 0r continuous filament may bepresoftened by a light treatment with steam or hot water, crimped in thestuifer crimper at a temperature not exceeding about F., packaged andsubjected to heat and moisture, for example, steam or hot water, orsubjected to a heated dye liquid for dyeing after which the excessliquid may be extracted and the package dried for setting the crimp.

The pretreatment may be omitted in some instances and if desired thecrimped silk core package may be impregnated with a thermosetting resinwhich may be dried and cured as in the previous examples.

Example XI Nylon yarn in continuous filament form may be hot crimped inthe sturifer crimper as above set forth, packaged and treated with a dyesolution which may be passed through the package preferably while heatedafter which the excess liquid may be extracted and the package heated bythe passage of hot air therethrough or by oven drying to dry the yarnand set the crimp therein.

Example XII The above treatment with or without a resin settingaccording to the results desired may be repeated for wool fibers and forother synthetic fibers such `as acrylic, modacrylic, polyesters,nitrilic, vinyl and oleinic fibers, and Vinyon, Orlon, Dacron and saran.

Referring to FIGS. 7 and 8 the package 41 is shown as placed on aspindle 70 for unwinding.

A friction washer 71 puts the necessary drag on the package during theunwinding operation. The tape S0 passes from the package 41 through apigtail guide 72 thence over a tension control device 73 which smoothesout the tape for reeling, thence onto a reel 74 driven by a motor 75.

The yarn 76 from the package 41 is fed through guides 77 and 78 thencethrough an eye 79, carried by an arm 80 projecting through a slot 81 ina housing 82. and connected to actuate an arm 84 pivoted at 85 andadapted to actuate a micro-switch 86. The arm 84 carries at its endweights 87 which are adjustable for controlling the tension of the yarn76. The yarn 76 passes yfrom the eye 79 to a fixed guide 88, and to atake-up device such as a constant speed Winder (not shown) where it iswound onto a cone or spool to form a yarn package of the usual type.

The micro-switch 86 is connected to control the operation of the motor75 so as to exert a pull on the tape when the tension on the yarnincreases and to stop the motor 75 when the `tension on the yarndecreases. In this way a substantially constant quantity of yarn ismaintained at the discharge point at the bite of the tape 50 on thepackage 41. As more yarn is pulled from the package the discharge pointrecedes into the area held cornpacted by the tape 50 which increases thedrag on the yarn 76. This increased tension closes the micro-switchmomentarily and causes the motor 75 to pull the tape and thus turn thepackage .to advance a further quantity of the core to the dischargepoint. This operation continues until the entire quantity of yarn hasbeen withdrawn from the package and wound onto a cone or other form ofpackage.

The above described method and apparatus is yparticularly suitable forimparting a permanent crimp to silk fibers and to acrylic, modacrylic,nitrilic, Vinyl and olefinic fibers to produce therefrom a continuousfilament yarn having saw tooth type crimps which are permanently settherein since these fibers require a more extended treatment for thesetting of the crimp than can be obtained in the usual stuffer crimper.The core package of the present application permits these fibers to besubjected to a setting treatment for the period of time required forimparting a permanent set to the crimp so that the bulk effect producedin the yarn remains throughout the useful life of the yarn and isresistant to the usual cleaning and pressing steps to which the yarn orthe fabric or garments fabricated therefrom may be subjected.

What is claimed is:

1. Apparatus for crimping and packaging textile fibers comprising abored tube forming a crimping chamber having inlet and discharge ends, apair of feed rolls positioned to feed said fibers into the inlet end ofsaid tube against a mass of previously crimped fibers held compactedtherein and to exert pressure for advancing said mass of fibers alongsaid tube to the discharge end thereof, said discharge end having across section substantially coextensive With the bore of said tube fordischarging the mass of crimped fibers as a continuous corecorresponding in section to the bore of said tube, a package Windercomprising a rotatable spindle, carrying a package support, a tapesupply, means feeding said tape from said supply to said support forWinding thereon in successive convolutions in superimposed layers, thedischarge end of said tube being disposed substantially within the biteof said tape with said package at the point of winding whereby the coreis wound with said tape in successive convolutions and is held confinedand compacted by said tape with successive convolutions of said coreseparated by said tape. Y

2. Apparatus according to claim 1 having take-up means driving saidspindle and positive feed means feeding said tape for winding thereon.

3. Apparatus as set forth in claim 2 in which said positive feed meansincludes a constant speed drive con- 8 nected to feed said tape at apredetermined ratio to the speed of said rolls.

4. Apparatus as set forth in claim 2 having switch means for controllingthe operation of said apparatus and means responsive to failure of saidtape feed to release said switch for stopping said apparatus.

5. Apparatus as set forth in claim 1 having a driven feed roll for saidtape, a pivoted member connected to hold said tape in driving engagementwith said last mentioned roll, a master switch for controlling theoperation of said apparatus, a tape controlled member adapted tomaintain said switch closed when tape is being properly fed, and torelease said switch in response to tape failure, said last means beingalso adapted to be manually positioned to hold said pivoted member outof contact with said tape to allow the apparatus to be operated withoutfeeding said tape.

6. Apparatus as set forth in claim 1 having traversing means connectedto cause said package support to traverse with respect to said tube forlaying the core and tape in successive convolutions in a helical layer.

7. Apparatus as set forth in claim 6 in which said traversing means isreciprocated for Winding said core and tape in successive layers.

8. Apparatus as set forth in claim 1 in which said tube is mounted formovement to conform to the diameter of said package as successive layersare wound thereon, and said package is traversed with respect to saidtube for laying the convolutions in layers.

, 9. Apparatus as set forth in claim 1 in which said tube is articulatedto provide a movable discharge end, said last end being movable toconform to changes in diameter of said package as the windingprogresses.

10. Apparatus as set forth in claim 9 in which the discharge end of saidtube is pivoted with respect to the remainder of said tube and isspring-pressed toward said package.

11. Apparatus as set forth in claim 1 in which the discharge end of saidtube is formed with a curved surface conforming generally to the contourof said package.

References Cited in the file of this patent UNITED STATES PATENTS712,986 Wardell Nov. 4, 1902 1,437,341 Dreaper Nov. 28, 1922 2,155,312Houtzaager Apr. 18, 1939 2,285,667 Kontz June 9, 1942 2,366,336 HullJan. 2, 1945 2,369,395 Heymann Feb. 13, 1945 2,509,347 Jackson May 30,1950 2,523,502 Dewas Sept. 26, 1950 2,623,266 Hemmi Dec 30, 19522,740,992 Shattuck Apr. 10, 1956 2,758,357 Goodhue Aug. 14, 19562,758,358 Shattuck Aug. 14, 1956 2,908,044 Whitney Oct. 13, 19592,913,802 Barnett Nov. 24, 1959

